CHAPTER 7 BRACKET UNIT

Transcription

1 CHAPTR 7 BRACKT UNIT STRING HANDL DISASSMBLING TH STRING HANDL CHCKING TH STRING HANDL ASSMBLING TH STRING HANDL BOTTOM COWLING RMOVING TH BOTTOM COWLING CHCKING TH BOTTOM COWLING INSTALLING TH BOTTOM COWLING SHIFT ACTUATOR DISASSMBLING TH SHIFT ACTUATOR RMOVING TH BRACKT...7- CHCKING TH SHIFT ACTUATOR...7- ASSMBLING TH SHIFT ACTUATOR UPPR CAS RMOVING TH UPPR CAS CHCKING TH UPPR CAS INSTALLING TH UPPR CAS DISASSMBLING TH UPPR CAS CHCKING TH XHAUST MANIFOLD ASSMBLING TH UPPR CAS STRING ARM RMOVING TH STRING ARM CHCKING TH STRING ARM INSTALLING TH STRING ARM CLAMP BRACKTS RMOVING TH CLAMP BRACKTS CHCKING TH CLAMP BRACKTS INSTALLING TH CLAMP BRACKTS

2 STRING HANDL 7 STRING HANDL DISASSMBLING TH STRING HANDL Throttle cable Throttle cable 3 Grommet 4 Bolt (with washer) 5 Bolt (with washer) 6 Steering handle cover 7 Collar 8 Collar 9 Plain washer 0 Wave washer Screw Handle 3 Washer Continued on next page. 7-

3 STRING HANDL 4 Compression spring 5 Bushing 6 Bolt 7 Self-locking nut 8 Steering friction 9 Throttle lever 0 Steering handle 7-

4 STRING HANDL CHCKING TH STRING HANDL Check: Steering friction Throttle lever Crack/damage Replace. Throttle cable 3 Bent/broken Replace. ASSMBLING TH STRING HANDL. Install: Steering handle Throttle lever Throttle friction 3. Connect: Throttle cable (loose cable side) Throttle cable (tight cable side) NOT: Connect the inner cable end in the groove, and fit the outer cable end into the hole. Apply Yamaha grease A (water resistant grease) to the throttle lever and throttle cable. 7-3

5 STRING HANDL 3. Install: Bushing 3 Compression spring Washer 3 4 Handle 4 NOT: Align the throttle lever shaft end with the hole in the handle. After installing steering handle, make sure the movement of throttle cables by moving it. 4. Install: Plain washer Wave washer Collar 3 Steering handle 4 Collar 5 Steering handle cover 6 Bolt 7 NOT: Apply Yamaha grease A (water resistant grease) to the throttle cables, washers and the steering handle crown. 5. Install: Throttle cables (through bottom cowling) Grommet NOT: Pass the throttle cables through the steering handle on the steering bracket. Be sure the throttle cable is routed correctly. 7-4

6 BOTTOM COWLING BOTTOM COWLING RMOVING TH BOTTOM COWLING Nut 4 Collar 4 3 Grommet 4 4 Washer 4 5 Bottom cowling 6 Grommet 7 ngine stop switch 8 Choke knob 9 Grommet 0 Grommet Grommet Spring pin 3 Throttle lever Continued on next page. 7-5

7 BOTTOM COWLING 4 Bushing 5 Throttle control shaft 6 Friction spacer 7 Bolt (with washer) 8 Clamp lever 9 Bushing 0 Wave washer Clamp lever 7-6

8 BOTTOM COWLING CHCKING TH BOTTOM COWLING. Check: Bottom cowling Crack/damage Replace.. Check: Clamp lever Wear/damage Replace. NOT: Apply Yamaha grease A (water resistant grease) or replace parts as required. 4 3 INSTALLING TH BOTTOM COWLING. Install: Bushing Throttle control shaft Throttle lever 3 Spring pin 4 NOT: Always use the new spring pin.. Install: Bottom cowling Nuts NOT: Apply Yamaha grease A (water resistant grease) to the clamp lever shaft. 7-7

9 SHIFT ACTUATOR SHIFT ACTUATOR DISASSMBLING TH SHIFT ACTUATOR Rubber seal Rubber seal 3 Bolt (with washer) 4 4 Nut 5 Washer 6 Bracket 7 Gasket 8 Nut 9 Washer 0 Bolt Bolt (with washer) Bracket 3 Dowel pin Continued on next page. 7-8

10 SHIFT ACTUATOR 4 Bushing 5 Compression spring 6 Compression spring 7 Shift cam plunger 8 Cotter pin Not reusable 9 Washer 0 Cotter pin Not reusable Washer Joint 3 Bolt 4 Shift lever 5 Grommet 6 Cam plate Continued on next page. 7-9

11 SHIFT ACTUATOR 7 Bushing 8 Grease nipple 9 Cotter pin Not reusable 30 Washer 3 Plate washer 3 Shift rod 33 Spring pin Not reusable 34 Shift rod lever 35 Plate washer 36 Collar 37 Shift rod 38 Torsion spring 7-0

12 SHIFT ACTUATOR RMOVING TH BRACKT Remove: Bolts (upper side) Bolt (under side) NOT: The bolt (under side) must be removed from the bottom side of the upper case. CHCKING TH SHIFT ACTUATOR. Check: Shift lever Shift cam plunger Cam plate 3 Joint 4 Shift rod lever 5 Shift rod 6 Shift rod 7 Wear/damage Replace. NOT: Apply Yamaha grease A (water resistant grease) or replace parts as required.. Check: Bracket Bracket (remote control attachment) Crack/damage Replace. 7-

13 SHIFT ACTUATOR 3. Check: Rubber seal Rubber seal Crack/damage Replace. ASSMBLING TH SHIFT ACTUATOR. Install: Bracket Collar Shift rod lever Shift rod 4 Spring pin 5 Joint 6 Cotter pin 7 Grease nipple 3 8 NOT: Always use the new spring pin and the cotter pin. Apply Yamaha grease A (water resistant grease) to the collar inner surface, grease nipple and shift rod.. Hook: Torsion spring NOT: Hook it onto the shift rod lever and the bracket. 3. Install: Cam plate NOT: Apply Yamaha grease A (water resistant grease) to the cam plate shaft. 7-

14 SHIFT ACTUATOR 4. Install: Shift cam plunger Compression spring Bushing NOT: Apply Yamaha grease A (water resistant grease) to the shift cam plunger. 5. Install: Shift lever Bolt Arm 3 T R.. Bolt N m (. kgf m, 8. ft lb) 4 6. Install: Bracket (to upper casing) Bolts Nut 3 (mount rubber front upper) Rubber seal 4 (over the bracket) T R.. Bolt N m (. kgf m, 8. ft lb) Nut 3 7 N m (.7 kgf m, 3 ft lb) 3 7-3

15 UPPR CAS UPPR CAS RMOVING TH UPPR CAS Bolt (with washer) Nut 3 Bolt (with washer) 4 Nut 5 Bolt (with washer) 6 Lower mount rubber housing 7 Mount rubber (side lower) 8 Lower mount cover 9 Mount rubber (front lower) 0 Nut Washer Upper case 3 Nut Continued on next page. 7-4

16 UPPR CAS 4 Bolt 5 Washer 6 Nut 7 Mount rubber (side upper) 8 Gasket 4 9 Bolt (with washer) 0 Mount rubber (front upper) 7-5

17 UPPR CAS CHCKING TH UPPR CAS Check: Upper case Crack/damage Replace. Mount rubber Wear/crack/damage Replace. INSTALLING TH UPPR CAS Install: Mount rubber (front upper) Mount rubber (side upper) with gaskets Nut 3 Upper case 4 (to swivel bracket) Nut 5 (side upper) Mount rubber 6 (side lower) Mount rubber 7 (front lower) Lower mount cover 8 Lower mount rubber housing 9 T R.. Nut 5 7 N m (.7 kgf m, 3 ft lb) Bolt (lower mount rubber housing 9 ) 7 N m (.7 kgf m, 3 ft lb) NOT: Make sure the lower mount rubber housing is installed with the UP mark pointing upward. 7-6

18 UPPR CAS DISASSMBLING TH UPPR CAS Bolt xhaust guide 3 Bolt 4 4 xhaust manifold 5 xhaust seal Not reusable 6 xhaust seal Not reusable 7 Cotter pin Not reusable 8 Gasket 9 Gasket Not reusable 0 Water tube Water seal rubber 7-7

19 UPPR CAS CHCKING TH XHAUST MANIFOLD Check: xhaust manifold xhaust guide Carbon deposits Clean. Crack/corrosion Replace. ASSMBLING TH UPPR CAS. Install: xhaust manifold xhaust guide xhaust seals 3 Gasket 4 NOT: Always use new gaskets and exhaust seals. If old ones are used, gas leakage may result due to invisible scratches or stretches.. Install: Water seal rubber Water tube NOT: Install the water seal rubber so that it aligns with the locating hole a in the upper case. 7-8

20 STRING ARM STRING ARM RMOVING TH STRING ARM Bolt Seal rubber 3 Bolt 4 4 Bracket 5 Dowel pin 6 Steering pivot shaft 7 Washer 8 Bushing 9 Friction piece 0 Bushing O-ring Not reusable Bushing 7-9

21 STRING ARM CHCKING TH STRING ARM. Check: Bracket Steering pivot shaft Crack/damage Replace.. Check: Bushing 3 Bushing 4 Friction piece 5 Wear/damage Replace. INSTALLING TH STRING ARM 0 Install: Bracket Steering pivot shaft Bushing 3 9 Bushing 4 Friction piece 5 O-ring 6 Washer 7 Washer 8 Dowel pin 9 (to pivot shaft) Bolt 0 Bolt (steering friction) NOT: Always use the new O-ring. Apply Yamaha grease A (water resistant grease) to the bushing, O-ring and the grease nipples. After installing the steering bracket, make sure the movement of steering pivot shaft by moving it. 7-0

22 CLAMP BRACKTS CLAMP BRACKTS RMOVING TH CLAMP BRACKTS Tension spring Tilt rod 3 Conical spring 4 Nut 5 Washer 6 Bolt 7 Collar 8 Clamp bracket cap 9 Nut 0 Clamp bracket plate Clamp bracket Clamp bracket 3 Clamp bracket bolt Continued on next page. 7-

23 CLAMP BRACKTS 4 Washer 5 Bushing 6 Tilt lever cover 7 Tilt lever 8 Torsion spring 9 Circlip 0 Pin Spring return lever Tilt lock rod 3 Tilt lock rod 4 Cotter pin 5 Pin 6 Tilt lock plate (outer) Continued on next page. 7-

24 CLAMP BRACKTS 7 Pin 8 Tension spring 9 Bolt 30 Shallow water lever 3 Cover 3 Tilt lock plate (inner) 33 Grease nipple 4 34 Swivel bracket 35 Spring pin 36 Stopper knob 37 Stopper shaft 7-3

25 CLAMP BRACKTS CHCKING TH CLAMP BRACKTS. Check: Clamp bracket (port side) Clamp bracket (starboard side) Swivel bracket 3 Crack/damage Replace.. Check: Tilt lock plate (outer) Tilt lock plate (inner) Shallow water lever 3 Tension spring 4 Tension springs 5 Bent/crack/damage Replace. 3. Check: Tilt rod Bent/damage Replace. Conical spring Crack/damage Replace. 4. Check: Tilt lever Tilt lever Tilt lock rod 3 Torsion spring 4 Crack/damage Replace. 5. Check: Bushing Wear/damage Replace. 7-4

26 CLAMP BRACKTS INSTALLING TH CLAMP BRACKTS. Install: Swivel bracket (with bushings) Shallow water lever Tension springs 3 Tilt lock lever 4 (inner) front side Tilt lock lever 5 (outer) rear side Pin 6 Cotter pin 7 NOT: Always use the new cotter pin. Apply grease to parts when specified.. Install: Swivel bracket Pin Tilt lever 3 Circlip 4 Tilt lock rod (hook to inner tilt lock plate) Tilt lock rod 6 (hook to tilt lever 7 ) Torsion spring NOT: Always use the new circlip. Apply water resistant grease to the pin and tilt levers. 7-5

27 CLAMP BRACKTS 3. Install: Clamp bracket (port side) Clamp bracket (starboard side) Transom clamp handle 3 Stopper shaft 4 Stopper knob 5 Spring pin 6 NOT: Always use the new pin and a spring pin. Apply Yamaha grease A (water resistant grease) to the transom clamp screw, stopper shaft and the grease nipple. 4. Install: Clamp bracket bolt Clamp bracket (starboard side) Washer 3 Swivel bracket 4 Torsion spring 5 Tilt lever 6 Washer 7 Clamp bracket 8 (port side) Nut 9 (clamp bracket bolt) Bolt 0 Collar Nut Tilt rod 3 (with conical spring 4 ) Tension spring 5 NOT: Place the tilt lever 6 inside the clamp bracket 8 (port side) as shown. T R.. Nut 9 45 N m (4.5 kgf m, 33 ft lb) 7-6